Dewatering unit and method of using the same

ABSTRACT

A dewatering unit in the form of a railcar having bogies thereon to move the unit on rail tracks. The dewatering unit has first and second ends, first and second sides, and a bottom that bound and define an interior chamber. A conveyor is provided in the interior chamber and screens are located in the bottom and first and second sides. A grizzly is located below an opening in the unit&#39;s top and above the conveyor. Stabilizing assemblies are deployed to contact the ground and lift some weight off of the bogies prior to loading. A solid material/liquid mixture is dropped through the opening and onto the grizzly which partially fractures the solid material. Further fracturing is undertaken by conveyor drag bars and crushers located adjacent the conveyor. Liquid drains from the unit through the screens. The dewatered solid material is lifted out of the unit by the conveyor.

BACKGROUND Technical Field

The present disclosure relates generally to methods and systems fordewatering solid materials from a solid/liquid mixture. In particular,the present disclosure is directed to a dewatering unit that may beutilized in rail/pad dump applications or in pit dump applications fordewatering coke or coal. Specifically, the present disclosure relates toa dewatering unit having movable connector members, a grizzly positionedbeneath each connector member, liquid-draining screens in the bottom andside walls, and a conveyor for moving the dewatered solids out of theunit. The dewatering unit may be in the form of a railcar including aplurality of rail bogies along with stabilizing assemblies that aredeployed to support at least some of the weight of the unit.

Background Information

Petcoke (i.e., petroleum coke) is a solid, coal-like material that maybe produced as part of an oil refining process. Petcoke may be producedby delayed a coking process or by a fluid coking process. During thecoking process, heat may be used to crack or break down largehydrocarbon molecules to produce petcoke. In some instances, the cokingprocess occurs in coking units also known as coking drums or cokingtowers that may be about 32 feet in diameter and around 100 feet tall. Alarge quantity of hardened coke builds up in the coking unit and istypically removed therefrom by boring a hole into the coke and thenusing high pressure water to blast pieces of the coke from the cokingunit. A mixture or slurry of water and petcoke flows out of the cokingunit and is typically deposited into a dewatering unit so that water canbe removed from the mixture or slurry.

U.S. Pat. No. 8,147,689 (Cogar) discloses a dewatering unit that issuitable for removing liquid from a mixture of coke and liquid thatexits a coking unit. The dewatering unit separates chunks of petcokefrom the large quantity of a liquid (such as water) used to unloadcoking towers. The dewatering unit includes upstanding walls that boundand define a containment region into which a mixture of petcoke andwater is introduced. The dewatering unit employs a conveyor having aseries of drag bars extending laterally across the conveyor. The dragbars are longitudinally spaced apart from each other. The drag bars areconnected at their ends to tandem continuous chains. The top flight ofthe chains and the drag bars ride on top of a stationary screening deck.The bottom flight of the chains and the drag bars ride on top of asluice deck. Water drain screens are provided in the screening deck. Thedischarge end of the dewatering unit is angled. In particular, thescreening deck and/or the conveyor angles upwardly toward the dischargeend of the dewatering unit. As the mixture of petcoke and water is movedthrough the dewatering unit by the drag bars, the water drops throughthe water drain screens and into the sluice deck. The ever-drier petcokerides on the conveyor and is discharged through the discharge end of theunit.

SUMMARY

While the dewatering unit disclosed in the Cogar U.S. Pat. No. 8,147,689functions well for its intended purpose, the present disclosure relatesto an improved dewatering unit that removes water from a petcoke/watermixture or slurry even faster. Additionally, the unit is able to moreeffectively reduce the size of the petcoke pieces that emerge from thedischarge end of the dewatering unit. Still further, the presentdisclosure is directed to a dewatering unit that may be engaged andmoved on a rail system, or may be utilized in crawler applications or asa stationary unit in a yard or at a pit.

A dewatering unit is disclosed herein. A first embodiment of thedewatering unit is in the form of a railcar having bogies thereon tomove the dewatering unit from one location to another along rail tracks.The dewatering unit has first and second ends, first and second sides,and a bottom that bound and define an interior chamber. A conveyor isprovided in the interior chamber and screens are located in the bottomand first and second sides. A grizzly is located below an opening in theunit's top and above the conveyor. Stabilizing assemblies are deployedto contact the ground and lift some weight off of the bogies prior toloading. A solid material/liquid mixture is dropped through the openingand onto the grizzly which partially fractures the solid material.Further fracturing is undertaken by conveyor drag bars and crusherslocated adjacent the conveyor. Liquid drains from the unit through thescreens. The dewatered solid material is lifted out of the unit by theconveyor.

It will be understood that the terms “liquid” and “water” may be usedinterchangeably in this description to represent the liquid component ofa mixture that is separated from a solid component using the device andmethod of the present disclosure. The terms “petcoke”, “coke”, “coal”,and “solid material” should be understood to represent the solidcomponent of the mixture that is separated from a liquid using thedevice and method of the present disclosure.

The apparatus is designed to dewater coke or coal, to contain fines, andto decrease the cost of reclaiming coke while protecting the water pumpsystem of the apparatus. The apparatus is configured in such a way tohelp ensure the safety of operators of the equipment. The apparatus maybe utilized for both rail/pad dump and pit dump applications. Theapparatus may be rail mounted, crawler mounted, or may be stationary.The apparatus may include a single drum or may include dual drums.

In one aspect, an exemplary embodiment of the present disclosure mayprovide a dewatering unit comprising a body having a first end, a secondend, a first side, a second side, and a bottom that bound and define aninterior chamber; a conveyor assembly provided in the interior chamberand adapted to move articles toward the second end; at least one firstscreen positioned below the conveyor assembly; and at least one secondscreen provided in one or both of the first side and the second side;wherein the at least one first screen and the at least one second screenis adapted to permit liquid to pass therethrough.

In another aspect, an exemplary embodiment of the present disclosure mayprovide a method of dewatering a mixture of solid material and water;said method comprising dropping a mixture of solid material and waterthrough an opening in a top of a dewatering unit and onto a conveyorassembly; transporting the solid material on the conveyor assemblytowards a second end of the dewatering unit; allowing some of the waterin the mixture to drain through one or more screens located below theconveyor assembly and out of the dewatering unit; allowing some of thewater in the mixture to drain through one or more screens located in oneor both of a first side and a second side of the dewatering unit and outof the dewatering unit. In one example, the method further comprisesbreaking up some of the solid material in the mixture using the grizzlylocated between the opening and the conveyor assembly. In one example,the method further comprises providing one or more bogies on thedewatering unit; engaging the one or more bogies on a pair of railtracks; and moving the dewatering unit from a first location to a secondlocation along the rail tracks. In one example, the method furthercomprises actuating a plurality of stabilizer assemblies provided on thedewatering unit; contacting a ground surface with a footing provided oneach of the actuator plurality of stabilizer assemblies; and supportingat least some of the weight of the dewatering unit on the plurality ofstabilizing assemblies.

In another aspect, and exemplary embodiment of the present disclosuremay provide a railcar comprising a body having a first end, a secondend, a first side, a second side, and a bottom that bound and define aninterior chamber; one or more bogies operatively engaged with the bodyand adapted to engage a pair of rail tracks; a conveyor assemblyprovided in the interior chamber and adapted to move articles toward thesecond end; at least one first screen positioned below the conveyorassembly, wherein the at least one first screen is adapted to permitliquid to pass therethrough.

In another aspect, and exemplary embodiment of the present disclosuremay provide a method of dewatering a mixture of solid material andwater; said method comprising engaging one or more rail bogies on arailcar with a pair of rail tracks; moving the railcar along the railtracks to a container holding a mixture of a solid material and aliquid; dropping a quantity of the mixture of solid material and liquidthrough an opening in a top of the railcar and onto a conveyor assemblylocated within an interior chamber of the railcar; transporting thesolid material on the conveyor assembly towards a second end of therailcar; allowing some of the liquid in the mixture to drain through oneor more first screens located below the conveyor assembly and out of therailcar. In one example, the method includes deploying a plurality ofstabilizing assemblies on the railcar to contact a ground surfaceadjacent the rail tracks prior to dropping the quantity of the mixturethrough the opening. In one example, the method includes allowing someof the liquid in the mixture to drain through one or more second screenslocated in one or both of a first side and a second side of the railcarand out of the railcar. In one example, the method includes breaking upsome of the solid material in the mixture using the grizzly locatedbetween the opening and the conveyor assembly. In one example, themethod includes aligning the opening in the top of the railcar with achute of the container; and raising a connector member on the railcarproximate the opening to engage the chute of the container prior todropping the quantity of the mixture through the opening.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

A sample embodiment of the disclosure is set forth in the followingdescription, is shown in the drawings and is particularly and distinctlypointed out and set forth in the appended claims. The accompanyingdrawings, which are fully incorporated herein and constitute a part ofthe specification, illustrate various examples, methods, and otherexample embodiments of various aspects of the disclosure. It will beappreciated that the illustrated element boundaries (e.g., boxes, groupsof boxes, or other shapes) in the figures represent one example of theboundaries. One of ordinary skill in the art will appreciate that insome examples one element may be designed as multiple elements or thatmultiple elements may be designed as one element. In some examples, anelement shown as an internal component of another element may beimplemented as an external component and vice versa. Furthermore,elements may not be drawn to scale.

FIG. 1 is a diagrammatic side elevation view of a pair of coking ovens,a first embodiment of a dewatering unit in accordance with the presentdisclosure, a secondary dewatering unit in accordance with the presentdisclosure, and a truck that receives product processed by thedewatering unit and secondary dewatering unit;

FIG. 2 is a block diagram showing the relationship between FIGS. 2A, 2Band 2C;

FIG. 2A is a side elevation view of a first end of the dewatering unitin accordance with the present invention and shown in FIG. 1;

FIG. 2B is a side elevation view a middle region of the dewatering unit;

FIG. 2C is a side elevation view of a second end of the dewatering unit;

FIG. 3 is a block diagram showing the relationship between FIGS. 3A, 3Band 3C;

FIG. 3A is a top plan view of the first end of the dewatering unit;

FIG. 3B is a top plan view of the middle region of the dewatering unit;

FIG. 3C is a top plan view of the second end of the dewatering unit;

FIG. 4 is a block diagram showing the relationship between FIGS. 4A, 4Band 4C;

FIG. 4A is a longitudinal cross-section of the first end of thedewatering unit;

FIG. 4B is a longitudinal cross-section of the middle region of thedewatering unit;

FIG. 4C is a longitudinal cross-section of the second end of thedewatering unit;

FIG. 5 is a top plan view taken along line 5-5 of FIG. 4A;

FIG. 6 is a top plan view taken along line 6-6 of FIG. 4B;

FIG. 7A is a longitudinal cross-section of the first end of thedewatering unit showing separation of coke and water therein;

FIG. 7B is a longitudinal cross-section of the middle region of thedewatering unit showing separation of coke and water therein;

FIG. 7C is a longitudinal cross-section of the second end of thedewatering unit showing separation of coke and water therein;

FIG. 8 is a longitudinal cross-section through a second embodiment of adewatering unit in accordance with the present disclosure;

FIG. 9 is a longitudinal cross-section through a third embodiment of adewatering unit in accordance with the present disclosure; and

FIG. 10 is a side elevation view of the secondary dewatering unit shownin FIG. 1.

Similar numbers refer to similar parts throughout the drawings.

DETAILED DESCRIPTION

An apparatus, system, and method of dewatering a mixture of a solidmaterial and a liquid is disclosed herein. By way of example only, theapparatus, system, and method is described with reference to a mixtureof petcoke and water. In particular, the apparatus, system, and methodis described with reference to petcoke removed from coking ovensutilizing high pressure water jets. It will be understood however thatthis apparatus, system, and method may be used in other applicationssuch as when a petcoke/water mixture is removed from pits and it isdesired to separate the solid material from the liquid. It will furtherbe understood that apparatus, systems, and methods based on theprinciples described herein may be used in other industries where solidmaterial is to be separated from a mixture.

Referring to FIG. 1 there is shown a side elevation view of a pair ofcoking ovens 10 and a system for separating petcoke from a mixture ofpetcoke and water. The system includes a first embodiment of adewatering unit in accordance with the present disclosure, generallyindicated by the reference number 12. The system may further include asecondary dewatering unit in accordance with the present disclosure,generally indicated by the reference number 14. The system may furtherinclude a truck 16 or other type of container, whether mobile orstationary. The truck 16 is illustrated by way of example only.

As shown in FIG. 1, dewatering unit 12 is positioned to receive amixture of petcoke and water from coking ovens 10. Secondary dewateringunit 14 is positioned to receive a processed end product from dewateringunit 12. Truck 16 is positioned to receive a further processed endproduct from secondary dewatering unit 14. It will be understood thatsecondary dewatering unit 14 may be omitted from the system and truck 16may be positioned to receive the processed end product from dewateringunit 12. In other instances, truck 16 may be omitted and the processedend product from dewatering unit 12 may be offloaded onto the ground orinto a pit or into any other desired types or style of receptacle orcontainer.

Referring to FIGS. 1 through 7C, the first embodiment dewatering unit 12will be described in greater detail. FIGS. 2A, 2B, and 2B show thedewatering unit separated into a first section, a central region, and asecond section, respectively, for clarity of illustration. FIG. 2 showshow FIGS. 2A, 2B, and 2C are related to each other. FIGS. 3A, 3B, and 3Cshow top plan views of the first section, central region, and secondsection, respectively, for clarity of illustration. FIG. 3 shows howFIGS. 3A, 3B, and 3C are related to each other. FIGS. 4A, 4B, and 4Cshow longitudinal cross-sections of the first section, central region,and second section, respectively, for clarity of illustration. FIG. 4shows how FIGS. 4A, 4B, and 4C are related to each other

Dewatering unit comprises a body having a first end 12 a, a second end12 b (FIG. 2C, a top 12 c, a bottom 12 d, a first side 12 e (FIG. 3A),and a second side 12 f. First end 12 a and second end 12 b define alongitudinal direction between them and a central longitudinal axis “Y”(FIG. 3A) extends between first end 12 a and second end 12 b. Top 12 cand bottom 12 d define a vertical direction therebetween. First side 12e and second side 12 f define a lateral or transverse directiontherebetween. First end 12 a, second end 12 b, top 12 c, bottom 12 d,first side 12 e, and second side 12 f bound and define an interiorchamber 12 g (FIG. 4A)

The first end 12 a, second end 12 b, top 12 c, bottom 12 d, first side12 e, and second side 12 f form a tank shell that is preferablyfabricated from carbon steel which is hot dip galvanized for corrosionresistance. The capacity of interior chamber 12 g varies depending onthe application to which dewatering unit 12 is to be put. For example,the capacity of interior chamber 12 g may range from about 18,000gallons up to about 20,000 gallons. It will be understood that anysuitably sized tank may be provided on dewatering unit 12.

As best seen in FIGS. 4A and 4B, one or more openings 12 h are definedinto chamber 12 g. In particular, the one or more openings 12 h aredefined in top 12 c and are in fluid communication with interior chamber12 g. Openings 12 h are utilized for a quantity of a petcoke/watermixture to be transferred from two spaced-apart coking ovens 10 (FIG. 1)to the interior chamber 12 g of dewatering unit 12. It will beunderstood that in order for the dewatering unit 12 to receive thepetcoke/water mixture from the two coking ovens 10 at substantially thesame time, the spacing between openings 12 h will need to besubstantially complementary to the spacing between the chutes 10 a ofthe coking ovens 10.

Dewatering unit 12 is illustrated in the attached FIGS. 2A-7C asincluding two openings 12 h but it will be understood that in otherexamples only one opening 12 h may be defined in top 12 c. When only oneopening 12 h is defined in top 12 c, then dewatering unit 12 will beutilized to receive a petcoke/water mixture from a single coking oven10. It will be understood in other applications, more than two openings12 h may be defined in top 12 c of dewatering unit 12 to enable apetcoke/water mixture to be received into chamber 12 g of dewateringunit 12 from more than two coking ovens 10.

Dewatering unit 12 is also provided with one or more overflow weirs 12 j(FIGS. 2B, 4B) in one or both of the first sides 12 e, 12 f. Theoverflow weirs 12 j help to capture any overflow or spillage that mayoccur when loading petcoke/water mixture from coking oven 10 throughopenings 12 h and into interior chamber 12 g and the interior chambergets too full. The overflow weirs 12 j may be provided with diverterplates 12 j′ (FIG. 4B) to direct spillage away from top 12 c and intoweirs 12 j so that the spillage may be captured and processed properly.As best seen in FIG. 4B, the overflow weirs 12 j are coarsely screenedwith screens 12 j″ (FIG. 2A) that filter out solid material (such aspetcoke and some fines) in the water that is moving into overflow weirs12 j and out of dewatering unit 12.

A connector member 18 is provided to limit access through each opening12 h and into interior chamber 12 g. Each connector member 18 includes avertically-oriented peripheral wall 18 a, a horizontally-oriented toprim 18 b, and a central bore 18 c. One or more actuators 20 are operablyengaged with each connector member 18 and with a portion of the top 12 cor first or second sides 12 e, 12 f of dewatering unit 12. Actuators 20are selectively operable to selectively raise and lower connector member18. It will be understood that actuators 20 may be of any suitable type.For example, hydraulic cylinders, electric cylinders or pneumaticcylinders may be suitable as actuators 20. When dewatering unit 12 ispositioned under coking ovens 10 (FIGS. 1, 2B) such that at least one ofthe connector members 18 is aligned with at least one chute 10 athereof, the associated actuators 20 are activated. Actuators 20 causethe associated connector member 18 to be raised upwardly relative to top12 c of dewatering unit 12 from a lowered position, i.e., a storageposition (FIGS. 2B and 4B) into a raised position, i.e., a use position(FIGS. 2A and 4A) with chute 10 a on coking oven 10. Once connectormember 18 is in the correct position, a valve 10 b (FIG. 1) on cokingoven 10 is opened and the petcoke/water mixture flows from coking oven10 into interior chamber 12 g. The raising of connector member 18relative to top 12 c helps to create the type of connection betweencoking oven 10 and dewatering unit 12 that will tend to reduce thepotential for spillage of the petcoke/water mixture flowing out of theexit 12 a onto and surrounding dewatering unit 12. Once thepetcoke/water mixture flow from coking oven 10 to dewatering unit 12ceases, actuators 20 are activated to lower connector members 18 fromthe connection position back into a storage position. In this storageposition, the vertical wall 18 a of connector member 18 is lowered intointerior chamber 12 g and rim 18 b rests on an exterior surface of top12 c or is moved downwardly toward the exterior surface. This is shownin FIG. 4B.

Referring to FIGS. 3A-4B, a grizzly 22 is positioned a distancevertically below a bottom end of each connector member 18. As shown inFIG. 3A, each grizzly 22 includes a plurality of bars 22 a and crossbars22 b that are arranged to define a plurality of spaces 22 c betweenthem. At least an upper surface of one or more bars 22 a and/or one ormore crossbars 22 b is convoluted to present a plurality of angular,upstanding teeth 22 d (FIG. 4A). One or more regions of each grizzly 22may be oriented at an angle relative to the interior surface of top 12c. In one example, the grizzlies 22 are configured to present a stepped,stair-like obstruction located beneath the chute of the connector member18 as is illustrated in FIG. 4A. Each grizzly 22 may be fabricated from3″ thick AR-400 steel and is shaped in a manner to create sharppenetrating teeth 22 d. The penetrating teeth 22 d help to break largesolid masses of petcoke falling from coking ovens 10 into a moremanageable size for handling and crushing by dewatering unit 12, as willbe further described herein. When the petcoke/water mixture flows out ofcoking oven 10 and through the bore 18 c of connector member 18, thelarger pieces of petcoke may strike the bars 22 a, crossbars 22 b,and/or teeth 22 d of grizzly 22 and may be fractured into smaller piecesthat then drop through openings 22 c. The larger pieces of petcoke mayalso “bounce” down the stepped configuration of the grizzly 22 andbecome further fractured.

Dewatering unit 12 also includes a conveyor assembly 24 that issubstantially similar to the conveyor assembly described in detail inU.S. Pat. No. 8,147,689 (the entire disclosure of which is incorporatedherein by reference). Conveyor assembly 24 differs in shape to theconveyor assembly disclosed in U.S. Pat. No. 8,147,689 but the basicstructure of the two conveyor assemblies are the same. As such, conveyorassembly 24 comprises a pair of laterally-spaced apart continuous chains24 a that are mounted around drive sprockets 24 b (FIG. 4C) and an idlersprocket 24 c (FIG. 4B). Conveyor assembly 24 is supported on a conveyortable 25 that includes a plurality of grates 25 a therein. Conveyortable 25 retains the chains 24 a a distance above an interior surface ofthe bottom 12 d of dewatering unit 12 and below grizzlies 22. Chains 24a form a continuous loop and conveyor table 25 divides the conveyorassembly into a top flight that is located above conveyor table 25 and abottom flight that is located below the conveyor table 25. The drivesprocket 24 b and idler sprocket 24 c drive the chains 24 a of conveyorassembly 24 such that the top flight moves in a direction from first end12 a to second end 12 b, and the bottom flight moves in a direction fromsecond end 12 b to first end 12 a. A plurality of drag bars 28 span thelateral distance between chains 24 a. Each end 28 a, 28 b (FIG. 6) ofeach drag bar 28 is secured to one of the chains 24 a. Drag bars 28 aretherefore oriented at right angles to longitudinal axis “Y” ofdewatering unit 12 and to the direction of travel of the chains 24 a.Drag bars 28 are longitudinally spaced-apart by spaces 30 from eachother. In some instances, adjacent drag bars 28 may be spaced from about1 foot up to about 3 feet from each other. The chains 24 a and drag bars28 together form the top flight and the bottom flight of conveyorassembly 24 as can be seen in FIG. 4A.

The conveyor chains 24 a are sealed conveyor chains that feature alloyheat-treated side bars, stainless steel pins, an inner brass ring seal,and a seal between the side bars. This seal arrangement holds tight ontothe pin and rotates within a groove in a bushing. This creates alabyrinth to help prevent debris from getting into the pin/bushing areaand thereby promotes longer chain life while preventing chain seizure.Additionally, each drag bar 28 (or flight) of conveyor assembly 24 ispreferably fabricated from solid alloy steel to promote long-lastinglife and dependability.

A drive assembly 32 (FIG. 3C) is provided on dewatering unit 12 fordriving drive sprocket 24 b. The drive assembly 32 drives chains 24 a intandem (i.e., in unison) and preferably is a variable rate chain driveassembly to control speed of conveyor assembly 24. One or more screens34 are defined in bottom 12 d of dewatering unit 12. Screens 34 arepositioned vertically below the bottom flight of conveyor assembly 24.Each screen 34 defines a plurality of openings therein that allow waterand fines to drop therethrough. The water may drop into a sluice locatedvertically below screens 34. The sluice may form part of the bottom 12 dof dewatering tank 12 or may be a separate component. The sluicepreferably is configured to direct any water collected therein in adirection opposite to the direction of travel of the petcoke carried bytop flight of conveyor assembly 24. As will be described later herein,during use of dewatering unit 12, petcoke blocks will drop onto conveyorassembly 24 and are moved by the top flight of the conveyor assembly 24toward second end 12 b. Water from the petcoke/water mixture dropsthrough spaces 30 between drag bars 28, through the openings in thegrates 25 a and ultimately through screens 34. The petcoke blocks onconveyor assembly 24 are moved toward second end 12 b and are ultimatelydischarged through an exit opening 12 k. The water flowing throughspaces 30, through grates 25 a tends to be swept along by drag bars 28in the second flight toward first end 12 a and drains through screens34. The water draining through screens 34 flows from the interiorchamber 12 g to outside the dewatering unit 12.

As best seen in FIGS. 4A, 4B, and 4C, the bottom 12 d of the body of thedewatering unit 12 includes a horizontally-oriented central section 36 athat is located vertically beneath the section of top 12 c in whichopenings 12 h are defined. The bottom 12 d also includes an angled firstsection 36 b and an angled second section 36 c. First section 36 bextends from proximate first end 12 a of dewatering unit 12 to a firstend of central section 36 a. First section 36 b is oriented at a firstangle α relative to central section 36 a. Second section 36 c extendsfrom a second end of central section 36 a to proximate second end 12 bof dewatering unit 12. Second section 36 c is oriented at a second angleβ relative to central section 36 a. The second angle β is shallower thanthe first angle α and therefore second section 36 c is a gentler slopethan is first section 36 b. This generally U-shaped bottom 12 d ofdewatering unit 12 tends to channel water into the central section 36 aand thereby over grates 25 a and screens 34.

As is evident from FIGS. 4A-4C, conveyor assembly 24 is shaped similarlyto the lower region of the body. Conveyor assembly 24 includes a centralportion 26A located vertically above central section 36 a of thedewatering unit's body, a first portion 26B that is located verticallyabove first section 36 b of the dewatering unit's body, and a secondportion 26C that is located vertically above second section 36 c of thedewatering unit's body. In other words, the conveyor assembly 24 is alsogenerally U-shaped when viewed from the side. Conveyor assembly 24passes around idler sprockets 38 a, 38 b (FIGS. 4A, 4B) are providedadjacent the regions where first section 36 b joins central section 36 aand where second section 36 c joins central section 36 a.

It should be noted that the angle α is steeper than the angle β.Additionally, the first section 36 b of the dewatering unit's body andtherefore the first portion 26B of conveyor assembly 24 is shorter thanthe second section 36 c of the dewatering unit's body and therefore thanthe second portion 26C of conveyor assembly 24. The steeper angle α andthe shorter first portion 26B of the conveyor assembly 24 helps toensure that petcoke material dropping through the bores 18 c ofconnector members 18 will be directed onto the central portion 26A ofconveyor assembly 24 and then move subsequently onto the second portion26C thereof. The shallower angle β and longer second portion 26C of theconveyor assembly helps to ensure that more water will tend to drain outthrough the spaces 30 between the drag bars 28 on the conveyor assembly24 and thereby through screens 34.

In accordance with another aspect of the present disclosure, one or moreopenings are defined in the first side 12 e and second side 12 f of thebody of dewatering unit 12. Vertically-oriented screens 40 arepositioned within the openings in first side 12 e and second side 12 f.The screens 40 include a plurality of openings that place interiorchamber 12 g in fluid communication with the air outside of thedewatering unit 12. Consequently, when the petcoke/water mixture flowsinto interior chamber 12 g of dewatering unit 12, some of the water inthe mixture will flow through the vertically-oriented screens 40 inaddition to the spaces 30 between drag bars 28 and thehorizontally-oriented screens 34. Screens 40 therefore help to permitmore rapid dewatering of the petcoke material in chamber 12 g. If asluice is provided below screens 34, screens 40 may be positioned suchthat water flowing therethrough will be directed downwardly into thesluice. Although not illustrated herein, it will be understood thatdoors may be provided on first side 12 e and second side 12 f toselectively close off the screens 40 so that water cannot flow out ofinterior chamber 12 g therethrough. As best seen in FIG. 6, each screen40 is substantially V-shaped when viewed from above. This shape providesadditional surface area relative to a planar screen and thereforeprovides even more openings for water to flow out of interior chamberthan would be possible if the screens were planar. It will be understoodthat in other examples planar screens will be used. Alternatively, aplurality of V-shaped screens and planar screens may be utilized.

The panels used for screens 34 and 40 preferably are fabricated from astainless steel material that is continuous TIG welded and is hardchrome wear-plated to help ensure strength and dependability of thescreens This construction also helps to ensure that the screens 34, 40are capable of taking impacts from large blocks of petcoke materialwhile allowing water to dissipate therethrough. The materials andconstruction also helps to extend the life of screens 34, 40. It will beunderstood that screens 34, 40 are removable so that they may berepaired or replaced as necessary.

In accordance with a further aspect of the present disclosure, one ormore baffle plates 42 (FIGS. 4A and 5) are provided on the interiorsurfaces of first side 12 e and second side 12 f. In particular, baffleplates 42 may be located inwardly of screens 40 and includes slots 42 athat allow water to flow therethrough and toward screens 50. Baffleplates 42 a are utilized to help to deflect petcoke material away fromscreens 40 and therefore aid in helping to reduce buildup of petcokematerial thereon. Baffle plates 42 may therefore aid in preventingblockage of screens 40. Additional baffle plates 42 may be provided onother areas of the interior surface of first side 12 e and second side12 f (other than above screens 40) to help reduce the tendency forpetcoke fines to build up thereon.

One or more crushers/pick breakers 44 (FIGS. 4C, 7C) are mounted indewatering unit 12 in a position where they will contact and crush orbreak material traveling up second portion 26C of conveyor assembly 24.Pick beaker 44 or crusher may be located anywhere along the length ofsecond portion 26C. Pick breaker 44 may be rotated about a transverseaxis by a motor 46 (FIG. 3C) so as to crush and breaker larger petcokematerial blocks into smaller pieces as the blocks travel up secondportion 26C. Pick breaker 44 is of a heavy duty steel construction andincludes AP style bearings and replaceable hard-faced bits. Pick breaker44 may be configured to reduce the feed size of material traveling upconveyor assembly 24 to a size of from about 6 inches up to about 8inches in size.

A breaker cleaner 48 (FIG. 4C) is mounted adjacent pick breaker 44 toclean petcoke materials from pick breaker 44 so as to ensure petcokematerials don't become lodged in pick breaker 44 and thereby reduce thepick breaker's effectiveness. The breaker cleaner 48 is configured tofree the pick breaker 44 of material buildup jammed between the throwsof pick breaker 44. It will be understood that another pick breaker andbreaker cleaner may be located on first portion 26B of conveyor assembly24 and or on central portion 26A thereof.

In accordance with another aspect of the present disclosure, dewateringunit 12 includes a translation mechanism for moving the dewatering unitfrom one location to another. In dewatering unit 12, that translationmechanism comprises one or more rail bogies 50 (FIGS. 2A and 2C) thatare operably engaged with the unit's body and are used to movedewatering unit 12 along rail tracks “RT”. Rail bogies 50 may be of anysuitable construction that will allow dewatering unit 12 to be moved ina first direction or a second direction along rail tracks “RT”. In thisfirst embodiment, dewatering unit 12 may include motors to drive bogies50. In other instances, bogies 50 may draw their power from rail tracks“RT” or from any other suitable source.

In accordance with another aspect of the present disclosure, dewateringunit 12 includes a plurality of stabilizing assemblies 52 (FIG. 2B).Stabilizing assemblies 52 may be provided at intervals along any regionof dewatering assembly 12 that is suitable for stabilizing assemblies 52to contact the ground on either side of rail tracks “RT” when deployed.In some example, stabilizing assemblies 52 are provided atspaced-intervals longitudinally from each other on one or both of firstside 12 e and second side 12 f of the dewatering unit's body.Additionally, stabilizing assemblies may be provided at laterally-spacedapart intervals from each other along first side 12 e and second side 12f. In this way, at least some of the weight of dewatering unit 12 may becollectively borne by stabilizing assemblies 52 (as described hereafter)in a balanced manner and such that the weight of dewatering unit 12 isdistributed generally equally to all of the plurality of stabilizingassemblies. Stabilizing assemblies 52 also aid in lifting some of theweight of the dewatering unit off of the rail tracks “RT”.

As best seen in FIG. 2B, stabilizing assemblies 52 include a housing 52a that is fixedly engaged within first side 12 e or second side 12 f ofthe dewatering unit's body, for example. A footing 52 b is movablysecured to housing 52 a and an actuator 52 c is engaged with housing 52a and footing 52 b. The actuator 52 c may be a hydraulic cylinder, apneumatic cylinder, an electrical cylinder, or any other component thatis able to move footing 52 b upwardly and downwardly relative to thehousing 52 a. FIG. 2B shows a first stability assembly 52 in a retractedposition where the footing 52 b is withdrawn upwardly toward bottom 12 dof dewatering unit 12. FIG. 2B also shows a second stabilizing assembly52 in a deployed state (or extended position) where the footing 52 b isin contact with the ground “GS”. When actuator 52 c is activated in afirst instance, footing 52 b is moved downwardly and outwardly fromhousing 52 a until a lower plate 52 d thereof contacts the ground “GS”.In a second instance, footing 52 b is moved upwardly and inwardly towardhousing 52 a until lower plate 52 d is lifted clear off the ground “GS”.The actuators 52 c, housing 52 a, and footing 52 b are of robustconstruction as their primary function is relieving the weight ofdewatering unit 12 from rail tracks “RT”. Stabilizing assemblies 52 willbe moved to a retracted or un-deployed position (lower plate 52 d out ofcontact with ground “GS”) when dewatering assembly 12 is to be movedfrom a first location to a second location along rail tracks “RT”. Whenthe desired second location is reached, stabilizing assemblies 52 may bemoved to an extended or deployed position (lower plate 52 d contactingthe ground “GS”). When some or all of the plurality of stabilizingassemblies 52 are moved to the extended position, at least some of theweight of dewatering assembly 12 (plus the weight of any petcoke/watermixture retained therein) is borne by stabilizing assemblies 52 insteadof or as well as by rail tracks “RT”. It is therefore useful to be ableto deploy the plurality of stabilizing assemblies 52 when petcoke/watermixture is being loaded into chamber 12 g from coking drums 10, forexample.

Although not illustrated herein, dewatering unit 12 may include a hitchassembly that enables the unit to be engaged with a powered vehicle tomove the unit along rail tracks “RT”. In other instances, bogies 50 mayinclude an onboard processor programmed to control movement ofdewatering unit 12. Dewatering unit 12 may further be provided with aprocessor in locations other than on bogies 50 that includes programmingthat may be accessed remotely by an operator to operate dewatering unit12. The operator may control a plurality of different functionsincluding but not limited to raising and lowering connector members 18,opening and closing doors (not shown) that cover screens 40, actuatingthe conveyor assembly 24, actuating the pick breaker(s) 44, actuatingbogies 50, and actuating stabilizing assemblies 52. Alternatively oradditionally, a control panel may be provided at any suitable locationon the body of dewatering unit 12. The control panel may includeswitches, buttons etc. that enable operator to start and stop operationof any driven component within dewatering unit 12. Dewatering unit 12may also be provided with various sensors that are operatively engagedwith an onboard processor, with the control panel or with a remotecomputer. The sensors may include proximity sensors (that determine, forexample, if the connector members 18 are aligned properly with the chute10 a of a coking oven 10); sensors that determine if the interiorchamber 12 g is filled to a predetermined limit, sensors that determineif the pick breaker(s) 44 are jammed, if the conveyor assembly 24 isstopped etc. Emergency shut-offs may also be operatively engaged withthe various driven systems.

Referring to FIGS. 1 and 7A-7C, dewatering unit 12 is used in thefollowing manner. The unit 12 is moved as indicated by arrows “A” (FIG.7A) to a position underneath coking ovens 10 (FIG. 1) by activatingbogies 50 to travel along rail tracks “RT to the desired position. Whenconnector members 18 are correctly positioned so as to be aligned withthe chutes 10 a of coking ovens, stabilizing assemblies 52 are deployedby moving them in the direction of arrow “B” (FIG. 2B) as previouslydescribed so that the weight of the dewatering unit 12 is at leastpartially lifted off the rail tracks “RT”.

Actuators 20 are then activated to raise connector members 18 in thedirection of arrow “C” (FIG. 7A) to each receive at least a portion ofthe associated chute 10 a of coking oven 10 therein. Motors 32 and 46are activated to initiate movement in conveyor assembly 24 in thedirection indicated by arrow “D” (FIG. 7A) and to rotate pick breaker 44in the direction indicated by arrow “E” (FIG. 7E). Valves 10 b on cokingovens 10 are moved to the open position and a quantity of chunks ofpetcoke “PC” mixed with a volume of water drops out of coking ovens 10and into interior chamber 12 g of dewatering unit 12 as indicated byarrow “F” (FIG. 7A). As the chunks/blocks of petcoke “PC” travel out ofthe bores 18 c of connector members 18, the chunks/blocks of petcoke“PC” will strike the grizzly 22 located directly below the associatedconnector member 18 and will be at least partially fractured as theydrop downwardly hitting the bars 22 a, crossbars 22 c, and teeth 22 dand fall through spaces 22 c and bounce off the grizzly 22.

The somewhat fractured petcoke blocks “PC” will fall downwardly in thedirection indicated by arrow “G” onto the drag bars 28 and be furtherfractured thereby. The water will drop through the spaces 30 betweendrag bars 28 in the direction indicated by the arrows “H” and throughthe openings in the screens 34 and into a sluice. The further-fracturedpetcoke blocks “PC” will start traveling along with conveyor assembly 24in the direction “D” toward second end 12 b of dewatering unit 12. Asthe petcoke blocks travel up the second portion 26C of conveyor assembly24 they will be contacted and be further broken down by the rotatingpick breaker 44. If some of the petcoke material becomes lodged betweenthe flights of pick breaker 44, the breaker cleaner 48 will remove thesame.

Water flowing through screens 34 will be directly toward first end 12 aof dewatering unit 12 is provided with a sluice. Alternatively, thewater will flow directly downward from bottom 12 d of unit 12. Since theopenings in the screens 34 are relatively small and the quantity ofwater and petcoke flowing into the dewatering unit 12 is large, thewater/petcoke material will start to fill the interior chamber 12 g. Ifthe doors (not shown) covering screens 40 in first and second side 12 e,12 f have not yet been opened, they will now be opened. Water will beginto flow out of interior chamber 12 g through the screens 40 as indicatedby the arrows “J” and thereby drain the interior chamber 12 gsubstantially faster than if only screens 34 are used on their own.Water flowing out of screens 40 may flow into the same sluice as thewater from screens 34. If no sluice is provided, the water will flowdownwardly over the lower regions of one or both of the first side 12 eand second side 12 f. It should be noted that any water spilling outfrom the chutes 10 a of coking ovens 10 or overflowing from connectionmembers 18 onto the exterior of the dewatering unit 12 will flow intoweirs 12 j and drain downwardly into interior chamber 12 g.

Petcoke blocks “PC” that have been reduced in size by pick breaker 44will reach the uppermost end 26D (FIG. 7C) of conveyor assembly 24 andwill drop downwardly out of an exit opening 12 k defined in second end12 b of dewatering unit 12. The petcoke blocks “PC” will drop out of thedewatering unit 12 in the direction indicated by arrow “K” (FIG. 7C).The petcoke blocks may be dropped into a secondary dewatering unit 14(FIG. 1) or into a truck 16, into a pit, onto the ground or into anyother type of desired receptacle.

Referring now to FIG. 8, a side elevation of a second embodiment of adewatering unit in accordance with the present disclosure is illustratedand is generally indicated at 112. Dewatering unit 112 comprises a bodyhaving a first end 112 a, a second end 112 b (FIG. 2C, a top 112 c, abottom 112 d, a first side 112 e, and a second side 112 e. First end 112a and second end 112 b define a longitudinal direction between them anda central longitudinal axis extends between first end 112 a and secondend 112 b. Top 112 c and bottom 112 d define a vertical directiontherebetween. The first side and the opposed second side 112 f define alateral or transverse direction therebetween. First end 112 a ofdewatering unit 112 may be substantially vertical instead of angledsimply because first end 112 a does not have to be shaped to accommodatea bogie 50, as will be later described herein.

First end 112 a, second end 112 b, top 112 c, bottom 112 d, the firstside 112 e, and the opposed second side 112 f bound and define aninterior chamber 112 g. Dewatering unit 12 is illustrated as definingtwo openings 12 h in top 12 c that are in fluid communication withinterior chamber 12 g. By contrast, dewatering unit 112 defines only oneopening in the top 112 c that is substantially identical in structureand function to opening 12 h and is in fluid communication with interiorchamber 112 g. Dewatering unit 112 is also provided with one or moreoverflow weirs 112 j in top 112 c that are of substantially the samestructure and function as overflow weirs 12 j. An exit opening similarto exit opening 12 k is also provided proximate second end 112 b ofdewatering unit 112.

A connector member 118 is provided to limit access through the openinginto interior chamber 112 g. The connector member 118 is substantiallyidentical in structure and function to connector member 18. One or moreactuators 120 are operably engaged with connector member 118 and with aportion of the top 112 c or first or second sides of dewatering unit112. Actuators 120 are selectively operable to selectively raise andlower connector member 118 in the same manner and for the same purposeas actuators 20 with respect to connector members 18.

A grizzly 122 is positioned a distance vertically below a bottom end ofconnector member 118. Grizzly 122 is of substantially the same structureand function as grizzlies 22. A conveyor assembly 124 is provided indewatering unit 112 that is of substantially the same overall structureand the same function as conveyor assembly 24 except that the shape andsize thereof may be slightly different from conveyor assembly 24. Inaccordance with another aspect of the present disclosure, one or moreopenings are defined in the first side and opposed second side 112 f ofthe body of dewatering unit 112. Vertically-oriented screens 140 arepositioned within the openings. The screens 140 include a plurality ofopenings that place interior chamber 212 g in fluid communication withthe air outside of the dewatering unit 112. Baffle plates 142substantially identical baffle plates 42 are provided on the interiorsurfaces of the first side 112 e and second side 112 f. In particular,baffle plates 142 may be located above screens 140 and are utilized tohelp to deflect petcoke material away from screens 140. Dewatering unitalso includes screens 134 in bottom 112 d.

Dewatering unit 112 is substantially identical in all other respects inregard to structure and function to dewatering unit 12 except for thetype of translation mechanism that is utilized. In dewatering unit 112instead of having bogies 50 as the translation mechanism to move thedewatering unit from one location to another, dewatering unit 112 isprovided with a translation mechanism in the form of a crawler assembly154. Crawler assembly 154 includes a track 154 a that travels aroundlongitudinally spaced-apart and transversely oriented axles 154 b.Crawler assembly 154 permits dewatering unit 112 to move insubstantially any direction across the ground. Bogies 50, on the otherhand, require rail tracks 50 and therefore can only move the dewateringunit 12 in specific directions and to specific locations. Dewateringunit 112 as illustrated also differs from dewatering unit 12 in that thestabilizing assemblies 52 are omitted therefrom. In one example, thecrawler assembly 154 may be vertically raiseable relative to bottom 112f of unit 112 and in this instance, support pads 156 provided on bottom112 f may contact the ground surface “GS’ and hold bottom 112 f a shortdistance above the ground surface “GS”. In other examples, however,stabilizing assemblies similar to stabilizing assemblies 52 may beincluded on dewatering unit 112 instead of the pads 156. Thesestabilizing assemblies may be utilized to lift weight off crawler 154.Crawler 154 may be selectively raised if the stabilizing assemblies aredeployed.

Although not illustrated herein, dewatering unit 112 may also include astaircase that enables an operator to gain access to top 112 c.

It will be understood that dewatering unit 12 or dewatering unit 112 maybe provided with any other suitable mechanism or equipment other thanbogies 50 or crawler assembly 154 that will enable the unit to be movedfrom one location to another.

Referring now to FIG. 9, there is shown a side elevation of a thirdembodiment of a dewatering unit in accordance with the presentdisclosure, generally indicated at 212. Dewatering unit 212 comprises abody having a first end 212 a, a second end 212 b (FIG. 2C, a top 212 c,a bottom 212 d, a first side 212 e, and a second side 212 e. First end212 a and second end 212 b define a longitudinal direction between themand a central longitudinal axis extends between first end 212 a andsecond end 212 b. Top 212 c and bottom 212 d define a vertical directiontherebetween. The first side 212 e and the opposed second side 212 fdefine a lateral or transverse direction therebetween. First end 212 a,second end 212 b, top 212 c, bottom 212 d, the first side 212 e, and theopposed second side 212 f bound and define an interior chamber 212 g.First end 212 a of dewatering unit 212 may be substantially verticalinstead of angled simply because first end 212 a does not have to beshaped to accommodate a bogie 50, as will be later described herein.

Dewatering unit 212 is illustrated as defining only one opening in top12 c that is in fluid communication with interior chamber 212 g. It willbe understood, however, that two or more openings may be definedtherein, similar to dewatering unit 12. Dewatering unit 212 is alsoprovided with one or more overflow weirs 212 j in top 112 c that are ofsubstantially the same structure and function as overflow weirs 12 j. Anexit opening similar to exit opening 12 k is also provided proximatesecond end 212 b of dewatering unit 212.

A connector member 218 is provided to limit access through the openinginto interior chamber 212 g. The connector member 218 is substantiallyidentical in structure and function to connector member 18. One or moreactuators 220 are operably engaged with connector member 218 and with aportion of the top 212 c or first or second sides of dewatering unit212. Actuators 220 are selectively operable to selectively raise andlower connector member 218 in the same manner and for the same purposeas actuators 20 with respect to connector members 18.

A grizzly 222 is positioned a distance vertically below a bottom end ofconnector member 218. Grizzly 222 is of substantially the same structureand function as grizzlies 22. A conveyor assembly 224 is provided indewatering unit 212 that is of substantially the same overall structureand the same function as conveyor assembly 24 except that the shape andsize thereof may be slightly different from conveyor assembly 24. Inaccordance with another aspect of the present disclosure, one or moreopenings are defined in the first side 212 e and opposed second side 212f of the body of dewatering unit 212. Vertically-oriented screens 240are positioned within the openings in the first and second sides. Thescreens 240 include a plurality of openings that place interior chamber212 g in fluid communication with the air outside of the dewatering unit212. Baffle plates 242 substantially identical baffle plates 42 areprovided on the interior surfaces of the first side 212 e and secondside 212 f. In particular, baffle plates 242 may be located abovescreens 240 and are utilized to help to deflect petcoke material awayfrom screens 240. Dewatering unit also includes screens 234 in bottom212 d.

Dewatering unit 212 is substantially identical in all other respects inregard to structure and function to dewatering unit 12 except thatinstead of having bogies 50 or a crawler assembly 154 to move thedewatering unit from one location to another, dewatering unit 212 isdesigned to simply rest upon the ground and remain stationary, i.e., inone location. Bottom 212 d may rest directly on the ground “GS” but inother instances, as illustrated in FIG. 9, a plurality of footings 256may contact the ground “GS” and hold bottom 212 d a short distance abovethe ground. In other examples, however, stabilizing assemblies similarto stabilizing assemblies 52 may be included on dewatering unit 212instead of the footing 256. These stabilizing assemblies may be utilizedto support the weight of dewatering unit 212 and help raise thedewatering unit 212 to a desired height off ground surface “GS”.

It will be understood that dewatering unit 212 may have an exteriorshape that is slightly different to the shape of the body illustrated inFIG. 9. For example, dewatering unit 212 may be configured to beidentical in shape to either of dewatering unit 12 or dewatering unit112 but will not include the bogie 50 or crawler assembly 154 becausedewatering unit 212 is not designed to be mobile. Dewatering unit 212lacks any type of mechanism that will enable it to move from onelocation to another. In some examples, dewatering unit 212 may be builtinto a supporting structure that will maintain dewatering unit 212 in afixed location. In this instance, the petcoke/water mixture has to bedelivered to dewatering unit 212 instead of the dewatering unit beingmoved to a coking drum or coking tower as is the case with dewateringunits 12 and 112. (It will of course be understood that in otherexamples, petcoke/water mixtures may be delivered to dewatering units 12or 112 if the dewatering unit is moved to some type of terminal thatincludes a conveying mechanism that transfers the petcoke/water mixtureto a hopper of some type.

It will further be understood that when water drains into a sluiceprovided on or adjacent to dewatering unit 12 or 112, the water mayaccumulate therein until a certain capacity is reached. The dewateringunit 12 or 112 may then be moved to a location where the accumulatedwater is removed from the sluice for further processing or recycling. Inthe dewatering unit 212, the sluice therein may be permanently placed influid communication with some type of drainage system that diverts thewater draining from the dewatering unit 212 for further processing orrecycling.

As indicated earlier herein, each of the dewatering units 12, 112, 212has a discharge or exit opening at the second end thereof, such as exitopening 12 k at second end 12 b of dewatering unit 12. Dewatered petcoketravels up the conveyor assembly 24, is crushed to an initially desiredsize by pick breaker 44 and then exits dewatering unit 12 through thedischarge/exit opening 12 k. The dewatered petcoke product may then befurther processed or utilized. In some instances, the dewatered petcokeproduct exiting any of the dewatering units 12, 112, 212 may not bequite dry enough in that it still includes too much water. In thisinstance, the dewatered petcoke product may be moved through secondarydewatering unit 14 shown in FIGS. 1 and 10. Referring to FIG. 10,secondary dewatering unit 14 includes a housing that has a first end 14a, a second end 14 b, a top 14 c, a bottom 14 d, a first side 14 e, andan opposed second side 14 f. Secondary dewatering unit 14 defines anelongate chute 14 g that is mounted on a frame 14 h such that the chute14 g is oriented at an angle. Frame 14 h is supported on one or morebogies 50 substantially similar to the bogies 50 on dewatering unit 12.Stabilizing assemblies 52 may also be provided on secondary dewateringunit 14.

Chute 14 g includes an intake 14 j at a lower end and an outlet 14 k ata higher end. Intake 14 j includes an opening on an upper surfacethereof such that dewatered petcoke product from dewatering unit 12 or112 or 212 may drop into the intake 14 j. A conveyor assembly similar instructure to conveyor assembly 24 is provided in chute 14 g to movedewatered petcoke product from intake 14 j to outlet 14 k. Because chute14 g is similar a rectangular cube in shape with a hollow channelpassing from intake 14 j to outlet 14 k, the conveyor assembly providedtherein will be similar in configuration to the second portion 26C ofthe conveyor 24 in dewatering unit 12. A plurality of screens 14 n ispositioned below at least a portion of the conveyor assembly 24 providedin secondary dewatering unit 14. Water that drains off of the alreadypreviously dewatered (but not fully dewatered) end product will flowdownwardly along an interior surface of the bottom wall of the chute 12g until it reaches screens 14 n. The water will then drain throughscreens 14 n and into a sluice, such as sluice 14 p below chute 14 g.One or both of the intake 14 j and the outlet 14 k may comprise a drivencrusher unit that will further break down petcoke fed into the intake 14j. FIG. 10 illustrates a secondary dewatering unit 14 having a crusherunit at the outlet 14 k and being driven by a motor 14 m. Preferably,the crusher unit has high throughput capacity and is of a type that isrobust and requires little maintenance. The crusher unit may becustomized to produce any desired size end product. The crusher unit mayinclude a direct drive with torque-limiting devices and may have avariable frequency drive (VFD). Additionally, the crusher unit may havelarge bearings and excellent seal arrangements. The hoppers on thecrusher unit may be lined with CCO or AR400 to give the unit a longlife. The bits on the crushers in the crusher unit may be carbidetipped.

After processing by secondary dewatering unit, the now additionallydewatered petcoke will drop out of an opening defined in the outlet 14 kand into a truck 16 (FIG. 1) or into a pit, or onto the ground, or intoanother receptacle.

It will be understood that utilizing appropriately sized and constructedgrizzly assemblies 22, 122, 222, pick breakers 44 and/or crushers,petcoke processed by dewatering units 12, 112, 212 and possiblyadditionally by secondary dewatering unit 14 and any crusher unitsthereon, may be broken down to a desired end product size with a desiredwater content. It will be understood that more than one secondarydewatering unit may be utilized as part of the dewatering systemillustrated in FIG. 1.

Dewatering units 12, 112, 212 disclosed herein aid in removing the needfor operators and other personnel to work under or near coking ovens 10.This increases workplace safety since hot petcoke which is transferredfrom coking ovens 10 to any of the dewatering unit 12, 112, 212 iscontained within the interior chamber 12 g, 112 g, 212 g at all timesthrough the dewatering processes. This arrangement also helps to ensurethat operators and other personnel have less exposure to contaminantswithin the material being processed. Additionally, all actuated gatevalves, level sensors and zero speed switches may be provided on thedewatering units 12, 112, 212 in located that ensure that operators arenot near the equipment performing the dewatering and resizing of thepetcoke material. Additionally, the dewatering units 12, 112, 212disclosed herein tend to have large containment tanks (i.e., interiorchambers 12 g) and this helps to reduce spillage from possible blowouts.

It will be understood that dewatering units 12, 112, 212 (along with thesecondary dewatering unit secondary dewatering unit 14) are customengineered to receive feed from coking ovens 10, size the feed to thedesired end-product specification, and transport the product to thedesired location, thereby eliminating unnecessary additional handling.The dewatering units 12, 112, 212 and second dewatering unit secondarydewatering unit 14 may be utilized to load rail cars, trucks, storagebins, and/or dump product onto containment pads etc. The majority of thewater used to remove petcoke from coking oven 10 is removed from thepetcoke utilizing the dewatering units 12, 112, 212 and secondarydewatering unit secondary dewatering unit 14. The pick breakers andcrusher units also help to remove an additional quantity of water fromthe petcoke material. Sizing of the petcoke material during thedewatering process through the use of grizzlies 22, 122, 212, pickbreakers such as pick breaker 44, and crusher units (such as those onsecondary dewatering unit 14) also presents multiple benefits in that noadditional handling is required to get the petcoke to a desired sizespecification. The grizzlies and pick breakers help to process a drierpetcoke product into any secondary dewatering unit secondary dewateringunit 14 than would be the case if the petcoke product was not beingbroken down in size during dewatering in dewatering units 12, 112 or212.

It will be understood that while the dewatering units 12, 112, 212 andsecondary dewatering unit 14 disclosed herein have been discussed withrespect to coking drums and production of petcoke, these units may beutilized with any other type of product that requires dewatering andsizing. If any other product does not require resizing, then thegrizzlies, pick breakers and crusher units may be omitted from thedewatering system.

Additionally, the dewatering units 12, 112, 212, and secondarydewatering unit 14 disclosed herein tend to contain the vast majority offines that normally escape in a dewatering process and return to jettank pumps. The units 12, 112, 212, and secondary dewatering unit 14thereby reduce the number of man-hours typically required to reclaim andhandle fines and also help to extend the life of jet pumps.

The configuration of units 12, 112, 212, and secondary dewatering unit14 is such that the pick breaker, crusher unit, and conveyor assemblycomponents are readily accessible for maintenance purposes and thistends to reduce the amount of downtime required to maintain themachines. As discussed earlier herein, the screen panels 34 a, 40 may beinstalled using bolts and therefore can easily be removed formaintenance purposes.

Various inventive concepts may be embodied as one or more methods, ofwhich an example has been provided. The acts performed as part of themethod may be ordered in any suitable way. Accordingly, embodiments maybe constructed in which acts are performed in an order different thanillustrated, which may include performing some acts simultaneously, eventhough shown as sequential acts in illustrative embodiments.

While various inventive embodiments have been described and illustratedherein, those of ordinary skill in the art will readily envision avariety of other means and/or structures for performing the functionand/or obtaining the results and/or one or more of the advantagesdescribed herein, and each of such variations and/or modifications isdeemed to be within the scope of the inventive embodiments describedherein. More generally, those skilled in the art will readily appreciatethat all parameters, dimensions, materials, and configurations describedherein are meant to be exemplary and that the actual parameters,dimensions, materials, and/or configurations will depend upon thespecific application or applications for which the inventive teachingsis/are used. Those skilled in the art will recognize, or be able toascertain using no more than routine experimentation, many equivalentsto the specific inventive embodiments described herein. It is,therefore, to be understood that the foregoing embodiments are presentedby way of example only and that, within the scope of the appended claimsand equivalents thereto, inventive embodiments may be practicedotherwise than as specifically described and claimed. Inventiveembodiments of the present disclosure are directed to each individualfeature, system, article, material, kit, and/or method described herein.In addition, any combination of two or more such features, systems,articles, materials, kits, and/or methods, if such features, systems,articles, materials, kits, and/or methods are not mutually inconsistent,is included within the inventive scope of the present disclosure.

The above-described embodiments can be implemented in any of numerousways. For example, embodiments of technology disclosed herein may beimplemented using hardware, software, or a combination thereof. Whenimplemented in software, the software code or instructions can beexecuted on any suitable processor or collection of processors, whetherprovided in a single computer or distributed among multiple computers.Furthermore, the instructions or software code can be stored in at leastone non-transitory computer readable storage medium.

All definitions, as defined and used herein, should be understood tocontrol over dictionary definitions, definitions in documentsincorporated by reference, and/or ordinary meanings of the definedterms.

The articles “a” and “an,” as used herein in the specification and inthe claims, unless clearly indicated to the contrary, should beunderstood to mean “at least one.” The phrase “and/or,” as used hereinin the specification and in the claims (if at all), should be understoodto mean “either or both” of the elements so conjoined, i.e., elementsthat are conjunctively present in some cases and disjunctively presentin other cases. Multiple elements listed with “and/or” should beconstrued in the same fashion, i.e., “one or more” of the elements soconjoined. Other elements may optionally be present other than theelements specifically identified by the “and/or” clause, whether relatedor unrelated to those elements specifically identified. Thus, as anon-limiting example, a reference to “A and/or B”, when used inconjunction with open-ended language such as “comprising” can refer, inone embodiment, to A only (optionally including elements other than B);in another embodiment, to B only (optionally including elements otherthan A); in yet another embodiment, to both A and B (optionallyincluding other elements); etc. As used herein in the specification andin the claims, “or” should be understood to have the same meaning as“and/or” as defined above. For example, when separating items in a list,“or” or “and/or” shall be interpreted as being inclusive, i.e., theinclusion of at least one, but also including more than one, of a numberor list of elements, and, optionally, additional unlisted items. Onlyterms clearly indicated to the contrary, such as “only one of” or“exactly one of,” or, when used in the claims, “consisting of,” willrefer to the inclusion of exactly one element of a number or list ofelements. In general, the term “or” as used herein shall only beinterpreted as indicating exclusive alternatives (i.e. “one or the otherbut not both”) when preceded by terms of exclusivity, such as “either,”“one of,” “only one of,” or “exactly one of.” “Consisting essentiallyof,” when used in the claims, shall have its ordinary meaning as used inthe field of patent law.

As used herein in the specification and in the claims, the phrase “atleast one,” in reference to a list of one or more elements, should beunderstood to mean at least one element selected from any one or more ofthe elements in the list of elements, but not necessarily including atleast one of each and every element specifically listed within the listof elements and not excluding any combinations of elements in the listof elements. This definition also allows that elements may optionally bepresent other than the elements specifically identified within the listof elements to which the phrase “at least one” refers, whether relatedor unrelated to those elements specifically identified. Thus, as anon-limiting example, “at least one of A and B” (or, equivalently, “atleast one of A or B,” or, equivalently “at least one of A and/or B”) canrefer, in one embodiment, to at least one, optionally including morethan one, A, with no B present (and optionally including elements otherthan B); in another embodiment, to at least one, optionally includingmore than one, B, with no A present (and optionally including elementsother than A); in yet another embodiment, to at least one, optionallyincluding more than one, A, and at least one, optionally including morethan one, B (and optionally including other elements); etc.

When a feature or element is herein referred to as being “on” anotherfeature or element, it can be directly on the other feature or elementor intervening features and/or elements may also be present. Incontrast, when a feature or element is referred to as being “directlyon” another feature or element, there are no intervening features orelements present. It will also be understood that, when a feature orelement is referred to as being “connected”, “attached” or “coupled” toanother feature or element, it can be directly connected, attached orcoupled to the other feature or element or intervening features orelements may be present. In contrast, when a feature or element isreferred to as being “directly connected”, “directly attached” or“directly coupled” to another feature or element, there are nointervening features or elements present. Although described or shownwith respect to one embodiment, the features and elements so describedor shown can apply to other embodiments. It will also be appreciated bythose of skill in the art that references to a structure or feature thatis disposed “adjacent” another feature may have portions that overlap orunderlie the adjacent feature.

Spatially relative terms, such as “under”, “below”, “lower”, “over”,“upper”, “above”, “behind”, “in front of”, and the like, may be usedherein for ease of description to describe one element or feature'srelationship to another element(s) or feature(s) as illustrated in thefigures. It will be understood that the spatially relative terms areintended to encompass different orientations of the device in use oroperation in addition to the orientation depicted in the figures. Forexample, if a device in the figures is inverted, elements described as“under” or “beneath” other elements or features would then be oriented“over” the other elements or features. Thus, the exemplary term “under”can encompass both an orientation of over and under. The device may beotherwise oriented (rotated 90 degrees or at other orientations) and thespatially relative descriptors used herein interpreted accordingly.Similarly, the terms “upwardly”, “downwardly”, “vertical”, “horizontal”,“lateral”, “transverse”, “longitudinal”, and the like are used hereinfor the purpose of explanation only unless specifically indicatedotherwise.

Although the terms “first” and “second” may be used herein to describevarious features/elements, these features/elements should not be limitedby these terms, unless the context indicates otherwise. These terms maybe used to distinguish one feature/element from another feature/element.Thus, a first feature/element discussed herein could be termed a secondfeature/element, and similarly, a second feature/element discussedherein could be termed a first feature/element without departing fromthe teachings of the present invention.

An embodiment is an implementation or example of the present disclosure.Reference in the specification to “an embodiment,” “one embodiment,”“some embodiments,” “one particular embodiment,” or “other embodiments,”or the like, means that a particular feature, structure, orcharacteristic described in connection with the embodiments is includedin at least some embodiments, but not necessarily all embodiments, ofthe invention. The various appearances “an embodiment,” “oneembodiment,” “some embodiments,” “one particular embodiment,” or “otherembodiments,” or the like, are not necessarily all referring to the sameembodiments.

If this specification states a component, feature, structure, orcharacteristic “may”, “might”, or “could” be included, that particularcomponent, feature, structure, or characteristic is not required to beincluded. If the specification or claim refers to “a” or “an” element,that does not mean there is only one of the element. If thespecification or claims refer to “an additional” element, that does notpreclude there being more than one of the additional element.

As used herein in the specification and claims, including as used in theexamples and unless otherwise expressly specified, all numbers may beread as if prefaced by the word “about” or “approximately,” even if theterm does not expressly appear. The phrase “about” or “approximately”may be used when describing magnitude and/or position to indicate thatthe value and/or position described is within a reasonable expectedrange of values and/or positions. For example, a numeric value may havea value that is +/−0.1% of the stated value (or range of values), +/−1%of the stated value (or range of values), +/−2% of the stated value (orrange of values), +/−5% of the stated value (or range of values), +/−12%of the stated value (or range of values), etc. Any numerical rangerecited herein is intended to include all sub-ranges subsumed therein.

Additionally, any method of performing the present disclosure may occurin a sequence different than those described herein. Accordingly, nosequence of the method should be read as a limitation unless explicitlystated. It is recognizable that performing some of the steps of themethod in a different order could achieve a similar result.

In the claims, as well as in the specification above, all transitionalphrases such as “comprising,” “including,” “carrying,” “having,”“containing,” “involving,” “holding,” “composed of,” and the like are tobe understood to be open-ended, i.e., to mean including but not limitedto.

In the foregoing description, certain terms have been used for brevity,clearness, and understanding. No unnecessary limitations are to beimplied therefrom beyond the requirement of the prior art because suchterms are used for descriptive purposes and are intended to be broadlyconstrued.

Moreover, the description and illustration of various embodiments of thedisclosure are examples and the disclosure is not limited to the exactdetails shown or described.

What is claimed:
 1. A dewatering unit comprising: a body having a firstend, a second end, a first side, a second side, and a bottom that boundand define an interior chamber; a conveyor assembly provided in theinterior chamber and adapted to move articles toward the second end; atleast one first screen positioned below the conveyor assembly; at leastone second screen provided in one or both of the first side and thesecond side; wherein the at least one first screen and the at least onesecond screen are adapted to permit liquid to pass therethrough; and abaffle plate positioned between the at least one second screen and theinterior chamber.
 2. The dewatering unit according to claim 1, furthercomprising one or more stabilizing assemblies engaged with one or bothof the first side and the second side; wherein each stabilizing assemblyis movable between a retracted position and an extended position, andwhen in the extended position, a footing of the stabilizing assembly isadapted to contact a ground surface below the body.
 3. The dewateringunit according to claim 2, wherein each of the one or more stabilizingassemblies includes an actuator that moves the footing between theretracted position and the extended position.
 4. The dewatering unitaccording to claim 1, further comprising a translation mechanism adaptedto move the body across a ground surface.
 5. The dewatering unitaccording to claim 4, wherein the translation mechanism comprises one ormore rail bogies positioned below the bottom of the body, said one ormore rail bogies being adapted to move the body along rail tracks. 6.The dewatering unit according to claim 4, wherein the translationmechanism comprises a crawler assembly.
 7. A dewatering unit comprising:a body having a first end, a second end, a first side, a second side,and a bottom that bound and define an interior chamber; a conveyorassembly provided in the interior chamber and adapted to move articlestoward the second end; at least one first screen positioned below theconveyor assembly; and at least one second screen provided in one orboth of the first side and the second side; wherein the at least onefirst screen and the at least one second screen is adapted to permitliquid to pass therethrough; and wherein each of the at least one secondscreen is V-shaped when viewed from above.
 8. The dewatering unitaccording to claim 7, further comprising one or more stabilizingassemblies engaged with one or both of the first side and the secondside; wherein each stabilizing assembly is movable between a retractedposition and an extended position, and when in the extended position, afooting of the stabilizing assembly is adapted to contact a groundsurface below the body.
 9. The dewatering unit according to claim 7,further comprising a translation mechanism adapted to move the bodyacross a ground surface, wherein the translation mechanism comprises oneor more rail bogies positioned below the bottom of the body, said one ormore rail bogies being adapted to move the body along rail tracks.
 10. Adewatering unit comprising: a body having a top, a bottom, a first end,a second end, a first side, and a second side that bound and define aninterior chamber; at least one opening defined in the top, wherein theat least one opening is adapted to permit a mixture of a solid materialand to be placed into the interior chamber; at least one connectormember operatively engaged with the top adjacent the at least oneopening; said at least one connector member defining a boretherethrough, and at least one actuator operably engaged with the atleast one connector member, said at least one actuator being operable tomove the at least one connector member between a raised position and alowered position relative to the top; a conveyor assembly provided inthe interior chamber and adapted to move articles toward the second end;at least one first screen positioned below the conveyor assembly; and atleast one second screen provided in one or both of the first side andthe second side; wherein the at least one first screen and the at leastone second screen is adapted to permit liquid to pass therethrough. 11.The dewatering unit according to claim 10, further comprising a grizzlyprovided below the at least one opening.
 12. The dewatering unitaccording to claim 10, further comprising one or more stabilizingassemblies engaged with one or both of the first side and the secondside; wherein each stabilizing assembly is movable between a retractedposition and an extended position, and when in the extended position, afooting of the stabilizing assembly is adapted to contact a groundsurface below the body.
 13. The dewatering unit according to claim 10,further comprising a translation mechanism adapted to move the bodyacross a ground surface, wherein the translation mechanism comprises oneor more rail bogies positioned below the bottom of the body, said one ormore rail bogies being adapted to move the body along rail tracks.
 14. Adewatering unit comprising: a body having a top, a bottom, a first end,a second end, a first side, and a second side, that bound and define aninterior chamber; a conveyor assembly provided in the interior chamberand adapted to move articles toward the second end; at least one firstscreen positioned below the conveyor assembly; and at least one secondscreen provided in one or both of the first side and the second side;wherein the at least one first screen and the at least one second screenis adapted to permit liquid to pass therethrough; at least one overflowweir defined in one or both of the first side and second side proximatethe top of the body; and a screen provided in the at least one overflowweir.
 15. The dewatering unit according to claim 14, further comprisingone or more stabilizing assemblies engaged with one or both of the firstside and the second side; wherein each stabilizing assembly is movablebetween a retracted position and an extended position, and when in theextended position, a footing of the stabilizing assembly is adapted tocontact a ground surface below the body.
 16. A dewatering unitcomprising: a body having a first end, a second end, a first side, asecond side, and a bottom that bound and define an interior chamber; aconveyor assembly provided in the interior chamber and adapted to movearticles toward the second end; wherein the conveyor assembly isgenerally U-shaped when viewed from the first side; wherein thegenerally U-shaped conveyor assembly includes a central portion with afirst portion extending at a first angle in a first direction, and asecond portion extending at a second angle in a second direction, andwherein the second angle is smaller than the first angle; at least onefirst screen positioned below the conveyor assembly; and at least onesecond screen provided in one or both of the first side and the secondside; wherein the at least one first screen and the at least one secondscreen are adapted to permit liquid to pass therethrough.
 17. Thedewatering unit according to claim 16, further comprising a pick breakerprovided along the second portion of the conveyor assembly, said pickbreaker being rotatable about a transverse axis that extends between thefirst side and second side of the body.
 18. The dewatering unitaccording to claim 14, further comprising a translation mechanismadapted to move the body across a ground surface, wherein thetranslation mechanism comprises one or more rail bogies positioned belowthe bottom of the body, said one or more rail bogies being adapted tomove the body along rail tracks.
 19. The dewatering unit according toclaim 16, further comprising one or more stabilizing assemblies engagedwith one or both of the first side and the second side; wherein eachstabilizing assembly is movable between a retracted position and anextended position, and when in the extended position, a footing of thestabilizing assembly is adapted to contact a ground surface below thebody.
 20. The dewatering unit according to claim 16, further comprisinga translation mechanism adapted to move the body across a groundsurface, wherein the translation mechanism comprises one or more railbogies positioned below the bottom of the body, said one or more railbogies being adapted to move the body along rail tracks.
 21. A method ofdewatering a mixture of a solid material and a liquid; said methodcomprising: providing a dewatering unit comprising a body having a firstend, a second end, a first side, a second side, and a bottom which boundand define an interior chamber; providing a conveyor assembly in theinterior chamber of the dewatering unit, wherein the conveyor assemblyis generally U-shaped when viewed from the first side and comprises acentral portion, a first portion extending at a first angle and in afirst direction from the central portion, and a second portion extendingat a second angle and in a second direction from the central portion,wherein the second angle is smaller than the first angle; providing oneor more first screens below the conveyor assembly; providing one or moresecond screens in one or both of the first side and the second side ofthe dewatering unit; dropping a mixture of the solid material and theliquid through an opening in a top of the dewatering unit and onto theconveyor assembly; transporting the solid material on the conveyorassembly towards the second end of the dewatering unit; allowing some ofthe liquid in the mixture to drain through the one or more first screenslocated below the conveyor assembly and out of the dewatering unit;allowing some of the liquid in the mixture to drain through the one ormore second screens located in one or both of the first side and thesecond side of the dewatering unit and out of the dewatering unit. 22.The method according to claim 21, further comprising: breaking up someof the solid material in the mixture using a grizzly located between theopening and the conveyor assembly.
 23. The method according to claim 21,further comprising: providing one or more bogies on the dewatering unit;engaging the one or more bogies on a pair of rail tracks; and moving thedewatering unit from a first location to a second location along therail tracks.
 24. The method according to claim 23, further comprising:actuating a plurality of stabilizer assemblies provided on thedewatering unit; contacting a ground surface with a footing provided oneach of the actuator plurality of stabilizer assemblies; and supportingat least some of the weight of the dewatering unit on the plurality ofstabilizing assemblies.